Golf ball and thermoplastic material

Abstract

Disclosed herein are a novel thermoplastic material and a golf ball utilizing the thermoplastic material. The golf ball ( 10 ) preferably comprises a core ( 12 ), a cover ( 16 ) and optionally a boundary layer ( 14 ). At least one of the core ( 12 ), cover ( 16 ) or boundary layer ( 14 ) of the golf ball ( 10 ) comprises the thermoplastic material. The thermoplastic material comprises a partially to highly neutralized blend of a copolymer, a metallocene-catalyzed alpha-olefin with a softening comonomer, and a fatty acid or fatty acid salt.

We claim as our invention: 
     
       1. A process for forming a thermoplastic material, the process comprising:
 blending 30 to 60 parts of a copolymer of an alpha-olefin and an alpha, beta-unsaturated carboxylic acid with 30 to 60 parts of a metallocene-catalyzed alpha-olefin with a softening comonomer in an internal mixer to create a first mixture; 
 adding 40 to 70 parts of an oleic acid to the first mixture; 
 adding 5 to 15 parts of magnesium hydroxide to the first mixture; 
 mixing the oleic acid and magnesium hydroxide into the first mixture in the internal mixer to create a second mixture; 
 removing the second mixture from the internal mixer; 
 cooling the second mixture; 
 granulating the second mixture; 
 extruding the second mixture to neutralize a plurality of acid groups of the second mixture to form a fully neutralized mixture; 
 forming an article from the neutralized mixture. 
 
     
     
       2. The process according to  claim 1  wherein the article is a core for a golf ball. 
     
     
       3. The process according to  claim 1  wherein the article is a boundary layer for a golf ball. 
     
     
       4. A thermoplastic material consisting essentially of:
 approximately 36 parts of a zinc ionomer having an acid content ranging from 18.5 weight percent to 21.5 weight percent; 
 approximately 36 parts of a sodium ionomer having an acid content ranging from 18.5 weight percent to 21.5 weight percent; 
 approximately 28 parts of an ethylene-based butene plastomer; 
 approximately 33 parts zinc powder; and 
 approximately 67 parts of magnesium stearate; 
 wherein the thermoplastic material is neutralized from 50% to 100%. 
 
     
     
       5. A thermoplastic material consisting essentially of
 approximately 50 parts of an ethylene acrylic acid having an acid content of approximately 20%; 
 approximately 50 parts of an ethylene-based butene plastomer; 
 approximately 67 parts of an oleic acid; 
 approximately 11 parts of magnesium hydroxide 
 wherein the thermoplastic material is approximately 100% neutralized.